Bracket for positioning and protecting pipes in concrete

ABSTRACT

A bracket holds a rigid or flexible tube during the pouring of a concrete slab. The bracket has a base and a housing connected to the base. The tube curves around a first tube support on the housing before passing through an opening in the bottom of the housing. The tube and any members inside the tube are cut off so they end inside the housing and are then covered by a housing cap. The base is fastened to a form for the concrete slab. The height of the housing relative to the base is adjusted to place the cap at the planned surface of the concrete slab. After the concrete slab is formed the cap is removed and the cut members inside the housing are connected to other members or devices.

CROSS-REFERENCE TO RELATED APPLICATIONS

The application claims the benefit under 35 U.S.C. § 119(e) toProvisional Patent Application No. 62/703,376 filed Jul. 25, 2018, theentire contents of which are incorporated herein by reference.

BACKGROUND

Various tube forms such as pipes, wires or conduits are embedded inconcrete floors during construction. The tubes may be either flexible orrigid, and may themselves contain other elongated members such as wiresor pipes. The embedded tubes are typically held by brackets that curveor bend the tubes from a generally horizontal orientation to a verticalorientation, or if rigid, sustain them in position, so the end of thetube extends several inches above the surface of the concrete that ispoured over the bracket and tube. Unfortunately, after the concretehardens, the tube or its contents extending out of the concrete surfaceare often damaged. The damage can arise during finishing of theconcrete, especially by troweling machines, or when workers step on thetube, when wheels roll over the tube or when construction equipment orsupplies hit or are placed on the tube. The tube is often a conduitcontaining various tubes, wires or other elongated members (i.e.,conduit contents) that are also damaged along with the conduit by theabove actions.

The damaged tube or tube contents inhibit connection to other membersabove the concrete surface for their intended use. For example, a firstembedded tube may itself contain a second tube for carrying water whichis typically joined to a tubular coupling or connector by mechanicallyspreading the coupling or connector diameter and inserting an end of thesecond tube, and where the coupling or connector is subsequently used toform a suitable connection to join it to an adjacent tubular member.Because of damage to the first or second tubes, however, establishing aproper connection with the adjacent tubular member may require removingpart of the concrete surface around the first and second tubes to accessundamaged portions of the tubes that were formerly embedded within theremoved concrete. The cost and disruption of jack-hammering away enoughconcrete to establish a good connection is undesirable and may crack orotherwise weaken the poured floor—especially if too much concrete isremoved either intentionally or accidentally. There is thus a need for amethod and apparatus to help avoid or reduce damage to the ends of atube and its contents that are embedded in a concrete slab and to makeit easier and more reliable to connect to the tube or its contents thatpass through such concrete slabs.

One prior support for tubes in pipes s described in U.S. patentapplication Ser. No. 15/895,958 filed Feb. 13, 2018, the completecontents of which are incorporated herein by reference. This applicationdescribes a base fastened to a concrete form, with a housing and capenclosing the end of the tube and any electrical wires extending throughinto the housing. The housing is connected to a post that mates with thebase so the housing and post are separable from the base and can bepositioned vertically relative to the base to adjust for the height ofthe concrete. But the connection using the post may allow movement ofthe housing and the strength of the connection before being embedded inhardened concrete depends greatly on the strength of the post and itsconnection to the base. As the supports may be stepped on duringconstruction or pouring of concrete, damage of the support andmisalignment of the support and its housing can occur in someenvironments. There is thus a need for an improved method and device tocure the deficiencies of the prior art, and to support a tube, wire,cable or conduit in a curved configuration during construction, duringconcrete pouring and thereafter. There is a further need to adjust theposition of an enclosure of the tube, wires, cables etc., relative tothe top surface of a concrete surface.

Further, some of the prior art supports use curved supports that allowthe tubes held by the curved supports to slip out of the connection tothe support and become at least partially unsupported. That makes itdifficult to securely connect the tubes to the support and to accuratelyand/or reliably connect the tubes to the support. There is thus a needfor a support that allows an easy and fast connection of such tubes to asupport, while also securely and reliably connecting the tube to thesupport.

BRIEF SUMMARY

A bracket is provided that is configured to be fastened to a concreteform, with a curved passage for receiving the tube during use andchanging the direction of the tube, preferably through a continuouslycurved angle of 60° to 90° to avoid sharp bends, and typically from agenerally horizontal direction to a generally vertical direction. Thecurved support preferably has two parts. The first part isadvantageously part of the bracket and the second part is separate fromand movable relative to the bracket. When the first and second parts areconnected they resemble a curved tube. Advantageously the first andsecond parts snap together, using resilient latches and catches so thesecond part becomes connected to the bracket. That allows a user toplace the bracket and insert the tube easily into the first part of thecurved support and then attach the second part of the curved support tothe bracket to hold the tube in place in the bracket.

More than one such curved support can be provided on the bracket byhaving supports for tubes with two curved longitudinal axes parallel toeach other but laterally offset and in the same general plane, with thefirst part of each curved support facing in opposite lateral directions(e.g, one facing left the other facing right) so a second part can beconnected to the first part of each curved support. The brackets can beconnected together laterally by placing a latch on one bracket and amating catch on the other bracket, preferably on the base. Thus, singletube brackets can be connected, double tube brackets can be connected,or combinations thereof can be connected.

The bracket has a housing for the ends of any wires or cables or otherelongated members extending through the tubes. The housing isadvantageously formed as part of the bracket and advantageouslycomprises a cylindrical, tubular inner housing. The inner housing mayhave a generally closed bottom with an opening coinciding with thelocation of each curved support to allow the tube(s) to enter thehousing. A cap can close the top end of the inner housing, with the capand the top end of the inner housing being adjacent and advantageouslyslightly below the top surface of the finished concrete slab during useif the slab thickness corresponds close enough the height of the innerhousing when the bracket is fastened to the concrete form.

An outer housing fits over the inner housing with projections on one ofthe housings mating with recesses on the other housing to allow theouter housing to be positioned relative to the inner housing and thusadjust the height of the top end of the outer housing. The cap can beconnected to the top end of the outer housing. That allows the height ofthe housing relative to the top surface of the concrete to be adjusted.

Advantageously, a plurality of ridges extends outward from the wall ofthe inner housing, with one or more axial channels separating theridges. A plurality of mating projections, such as in the form oflocking lugs, extends inward from the wall of the outer housing with theprojections located to move axially along the slot or slots separatingthe ridges, with rotation of the outer housing moving some of theprojections between two adjacent ridges to interlock the inner and outerhousings. The engagement of a plurality of projections engaging aplurality of ridges provides a strong connection.

Advantageously, the inner housing is part of the bracket, with thebracket extending between the inner housing and the bottom of thebracket that connects to the form, to provide a strong and direct loadbearing path between the inner housing and the concrete form during use.Advantageously, the inner housing is connected to the upper end of thecurved supports which extend to the bottom of the bracket to providefurther support to the inner housing.

In more a bracket is provided for holding at least one tube having across-sectional diameter D while being embedded in a concrete slabhaving a planned thickness T. The bracket may have a base that in turnhas a toe end and a heel end with a plurality of feet extending downwardfrom the base and ending in the same horizontal plane. The bracket hasan inner cylindrical housing extending along a longitudinal housing axiswith that inner housing located above and connected to the heel end ofthe base by a housing support. The inner housing has an open top and agenerally closed bottom with at least one opening in the bottom toreceive the at least one tube during use. The inner housing also mayhave at least a first and second plurality of equally spaced,circumferential recesses on an outer surface of the inner housing, witheach plurality of circumferential recesses being in communication with adifferent axial channel on the outer surface of the inner housing andeach axial channel being parallel to the housing axis.

The bracket advantageously has a first curved support having a firstcurved central axis with the first curved support part extending alongthat first curved central axis and having a first end connected to thetoe end of the base and a second end connected to the inner housing atthe bottom of the inner housing. The first curved support part has across-section in a plane orthogonal to the first central axis largerthan D to receive the at least one tube during use. The bracket alsoadvantageously has a removable cap capable of covering the top of theinner housing.

This basic bracket may have further advantageous variations that mayinclude a tubular, outer housing having open ends and extending alongthe housing axis during use. The outer housing has a larger diameterthan the inner housing to fit over the inner housing during use. Theouter housing advantageously has a plurality of locking lugs extendinginward with the locking lugs located in columns so the locking lugs canmove axially along the channels separating the circumferential recesses.The locking lugs are advantageously spaced axially to align with thecircumferential recesses and are further sized to fit into thecircumferential recesses when the outer housing is rotated relative tothe inner housing to interlock the locking lugs with the circumferentialrecesses and adjust the relative positions of the inner and outerhousings along the longitudinal housing axis. Advantageously, the cap isconfigured to releasably connect to a top end of the outer housing.

In further variations, basic bracket may have the first curved supportinclude a second curved support part extending along the first centralaxis. The second curved support part may have a cross-section in a planeorthogonal to the first central axis and connected to the first curvedsupport part to form a tubular passage through the first curved supportwith a cross-section larger than D to receive the at least one tubeduring use. In still further variations, one of the first and secondcurved support parts has latches and the other of the first and secondcurved support parts has catches to connect the first and second curvedsupport parts together.

The first curved support part may also include a top stiffening flangeextending upward along a top side of the first curved support part andextending from a toe end of the first curved support part to the housingand connecting to the bottom of the housing. The top stiffening flangemay have one of a first plurality of catches or a first plurality oflatches and the second curved support part may have the other of thefirst plurality of catches or the first plurality of latches tointerlock the top stiffening flange and the second curved support part.

The first curved support part may also include a bottom stiffeningflange extending downward along a bottom side of the first curvedsupport part and extends from the toe end of the first curved supportpart to the housing support. The bottom stiffening flange may have oneof a second plurality of catches or a second plurality of latches andthe second curved support part may have the other of the secondplurality of catches or the second plurality of latches located tointerlock the stiffening flange and the second curved support part.

In still further variations, the base may have a generally rectangularshape when viewed from a bottom of the bracket, with a foot at eachcorner of the base. Advantageously, the base has an opening on eachopposing side of the first curved support part and at the toe end of thebase to allow entrainment by concrete during use. A bottom portion ofhousing support may include a triangular shaped plate so that a bottomportion of the outer housing can extend over a top portion of thetriangular shaped plate and thus lower the height of the outer housingrelative to the bracket and inner housing. The bracket may also includea central support extending from a middle of the base downward andending in the same plane as the feet.

The bracket may also include both first and second curved supports. Inthis configuration, the bracket advantageously includes a stiffeningflange extending upward from the base and extending from the toe end tothe heel end of the base and connecting to the bottom of the housing andthe housing support. The first curved support is advantageously locatedon a first laterally facing side of the stiffening flange and the secondcurved support is advantageously located on a second laterally facingside of the stiffening flange. The second curved support is constructedlike the first curved support and has a second central axis and a thirdand fourth curved support parts extending along that second centralaxis, with the third curved support part having a first end connected tothe base at the toe end of the base and has a second end connected tothe bottom of the inner housing and in communication with an inside ofthe inner housing. The third and fourth curved support parts cooperateto form a tubular passage through the second curved support having across-section larger than D in a plane orthogonal to the second centralaxis.

In further variations, either or both of the third and fourth curvedsupport parts may have a semi-circular cross-section with a diameterlarger than D. Further, the second or fourth support parts may have oneof a latch or catch to releasably connect to the other of a catch or alatch on a connector of a protective tube enclosing the tube having adiameter D during use of the bracket.

The bracket may have more than one outer housing connected in a verticalarrangement to extend the height of the stacked outer housings. Thebracket may thus include first and second tubular, outer housings eachhaving open ends and extending along the housing axis and each having alarger diameter than the inner housing. Each first and second outerhousing may have a plurality of locking lugs extending inward with thelocking lugs located in columns to move axially along the channelsseparating the circumferential recesses. The locking lugs areadvantageously spaced axially to align with the circumferential recessesand sized to fit into the circumferential recesses when either the firstor second outer housing is rotated relative to the inner housing tointerlock the locking lugs with the circumferential recesses and adjustthe relative positions of the inner and outer housings along thelongitudinal housing axis.

Advantageously, each first and second outer housing also has first andsecond rotational interlocking devices on respective top and bottom endsof each housing and configured so the second rotational interlockingdevice of the second outer housing may interlock with the firstrotational interlocking device of the first outer housing tointerconnect the first and second housings along the longitudinal axis,with the cap releasably engaging the first rotational interlockingdevice of the second outer housing, and the locking lugs of the firstouter housing engaging the circumferential recesses on the outer surfaceof the inner housing.

The inner and outer housings advantageously have three axial channels,two of which are spaced 90°, with the locking lugs located to fit inthose channels, and wherein the inner housing has first and second andthird pluralities of circumferential recesses each in communication withtwo of the three axial channels. The base may also include a rear flangelocated on an opposing side of the housing support as the first curvedsupport. Advantageously, the rear flange has two feet, each on anopposing side of the rear flange. Advantageously, the cross-section ofthe passage formed by the first and second curved parts is circular andhas a diameter greater than D. This ends the initial variations on thebasic bracket, but each of these above described, initial variations onthe basic bracket may be used in any combination with the othervariations, as may the variations described in more detail in thisapplication.

There is also provided a kit that may form a bracket for holding atleast one tube having a cross-sectional diameter D while being embeddedin a concrete slab. The kit may include a base having a toe end and aheel end with a plurality of feet extending downward from the base andending in the same horizontal plane. Each foot may have a passagetherethrough for a fastener. The bracket has an inner cylindricalhousing extending along a longitudinal housing axis with the innerhousing located above and connected to the heel end of the base by ahousing support. The inner housing has an open top and a generallyclosed bottom with at least one opening in the bottom to receive the atleast one tube during use. The inner housing also has at least a firstand second plurality of equally spaced, circumferential recesses on anouter surface of the inner housing, with each plurality ofcircumferential recesses being in communication with a different axialchannel on the outer surface of the inner housing and each axial channelbeing parallel to the housing axis.

The bracket also includes a first curved support having a first centralaxis and a first curved support part, with the kit including a secondcurved support part, each curved support part extending along the firstcurved central axis. The first curved support party has a first endconnected to the toe end of the base and a second end connected to theinner housing at the bottom of the inner housing. The first and secondcurved support parts form a tubular passage through the first curvedsupport where the passage has a cross-section in a plane orthogonal tothe first central axis larger than D. Advantageously, that cross-sectionis circular and the passage is a curved, cylindrical passage.

The kit also advantageously and preferably includes a first, tubular,outer housing having opposing and open, top and bottom ends, with thefirst outer housing having a larger diameter than the inner housing soit fits over the inner housing along the longitudinal axis. The firstouter housing has a plurality of locking lugs extending inward andlocated in columns to move axially along the channels separating thecircumferential recesses when the first outer housing moves along thehousing axis and over the inner housing. The locking lugs are spacedaxially to align with the circumferential recesses and are sized to fitinto the circumferential recesses when the first outer housing and theinner housing are rotated relative to each other to interlock thelocking lugs with the circumferential recesses. The kit also has aremovable cap for the top end of the outer housing.

In further variations, the kit may include all of the variations on thebasic bracket described above and described in more detail herein. Thekit may further include a second, tubular outer housing having open, topand bottom ends, the second outer housing having a larger diameter thanthe inner housing and fitting over the inner housing along thelongitudinal axis, the second outer housing having a plurality oflocking lugs extending inward and located in columns to move axiallyalong the channels separating the circumferential recesses, the lockinglugs spaced axially to align with the circumferential recesses and sizedto fit into the circumferential recesses, the second outer housinghaving third and fourth rotational interlocking devices on therespective top and bottom ends of the second outer housing, andconfigured to interlock with a different one of the first and secondinterlocking devices of the first outer housing to interconnect thefirst and second outer housings along the longitudinal axis during use.

The kit may also include a first outer housing that first and secondrotational interlocking devices on respective top and bottom ends of thefirst outer housing with the first rotational interlocking deviceconfigured to releasably connect to the cap. The kit may also include astiffening flange extending from the toe end to the heel end of the baseand connected to the housing support and the bottom of the housing. Thestiffening flange may have a first plurality of openings above the firstcurved support part and a second plurality of openings below the firstcurved support part, where the first and second plurality of openingsform catches for latches extending from the second curved support part.Advantageously, the first curved support part forms a portion of thestiffening flange.

The kit may also include two curved supports on one bracket.Advantageously, the bracket includes a stiffening flange with opposingfirst and second laterally facing sides with the first curved supportpart located on the first laterally facing side and a second curvedsupport located on the second laterally facing side of the stiffeningflange. The second curved support is like the first curved support butfacing a different way. The second curved support has a second centralaxis, the second curved support having third and fourth curved supportparts each extending along the second central axis. The third curvedsupport part has a first end connected to the base at the toe end of thebase and has a second end connected to the bottom of the inner housingand in communication with an inside of the inner housing. The third andfourth curved support parts form a tubular passage through the secondcurved support where the passage has a cross-section in a planeorthogonal to the first central axis larger than D and where thatpassage preferably has a circular diameter and comprises a curved,cylindrical passage.

There is also provided a method of supporting a tube during the formingof a concrete slab poured on a concrete form, using a bracket having abase and a housing with a cap enclosing a top opening of the housing toallow access to the tube when the tube is inside the housing. The tubeextends along a curved axis between the concrete form and the plannedsurface. The method includes securing the tube to the bracket where thebracket has a curved, tubular support extending along the curved axis.The curved tubular support is separated along a vertical planecontaining or parallel to the curved axis to form first and secondcurved support parts. The first curved support part is permanentlyaffixed to the bracket. The securing step includes placing the tube intothe first curved support part and passing an end of the support tubethrough an opening in the bottom of the housing. The housing includes aninner housing that is permanently affixed to the first curved supportpart. The securing step further including connecting the second curvedsupport part to the bracket to form the first support tube and enclosethe tube along the curved axis. The method also includes fastening thebracket to the concrete form.

In further variations, the method includes the step of passing a tubularouter housing having open ends and a larger diameter than the innerhousing along the housing axis until an axial column of axially spacedlocking lugs that extend inward from the outer housing align with one ormore axially spaced, circumferentially extending recesses that eachencircle a portion of an outer circumference of surface of the innerhousing; to adjust the relative height of the inner and outer housingsalong the housing axis. This variation also includes the step ofrotating one or both of the inner and outer housings and moving at leastsome of the locking lugs into the circumferential recesses. The rotatingstep may occur before the fastening step. The step may occur after thefastening step. The method may also include the step of connecting thesecond curved support part to the bracket by engaging a plurality oflatches on opposing top and bottom sides of the second curved supportpart with catches on opposing top and bottom sides of the first curvedsupport part.

BRIEF DESCRIPTION OF THE DRAWINGS

The above, and other features and advantages of the present inventionare further described in the following drawings and description in whichlike numbers refer to like parts throughout, and in which:

FIG. 1 is an exploded perspective view of a bracket assembly for asingle curved tube but without the tube;

FIG. 2A is a top perspective view of an integrally molded bracket shownin FIG. 1;

FIG. 2B is a bottom perspective view of the bracket of FIG. 2;

FIG. 3 is a top perspective view of an assembled bracket assembly ofFIG. 1 with a tube shown in phantom lines;

FIG. 4A is a side view of the bracket of FIG. 2 with catch openings fora curved support part, with the opposing view being the mirror imagethereof;

FIG. 4B is a right side view of the bracket of FIG. 4A;

FIG. 4C is a left side view of the bracket of FIG. 4A;

FIG. 4D is a top view of the bracket of FIG. 4A;

FIG. 4E is a bottom view of the bracket of FIG. 4A;

FIG. 5A is a top perspective view of the cap of FIG. 1;

FIG. 5B is a bottom perspective view of the cap of FIG. 5A;

FIG. 5C is a top view of the cap of FIG. 5A;

FIG. 5D is a front view of the cap of FIG. 5C, with the back view beingthe same;

FIG. 6A is a top perspective view of the outer housing of FIG. 1;

FIG. 6B is a bottom perspective view of the outer housing of FIG. 6A;

FIG. 7A is a front view of the outer housing of FIG. 6A;

FIG. 7B is a top view of the outer housing of FIG. 7A;

FIG. 7C is a left side view of the outer housing of FIG. 7B, with theright side view being the same;

FIG. 8 is an exploded perspective view of a bracket assembly for twocurved tubes held side-by-side, but without the tubes;

FIG. 9A is a top perspective view of the assembled bracket assembly ofFIG. 8 with the tubes shown in phantom;

FIG. 9B is a bottom perspective view of the assembly of FIG. 9A;

FIG. 10 is a top perspective view;

FIG. 11A is a side view of an integrally molded bracket shown in FIG. 8;

FIG. 11B is a right side view of the bracket of FIG. 11A;

FIG. 11C is a left side view of the bracket of FIG. 11A;

FIG. 11D is a top view of the bracket of FIG. 11A;

FIG. 11E is a bottom view of the bracket of FIG. 11A;

FIG. 12A is a top perspective view of two bracket assemblies and threetubes, connected side-by-side;

FIG. 12B is a bottom perspective view of the bracket assemblies of FIG.12A; and

FIG. 13 is a bottom view of the two bracket assemblies of FIG. 12A withan enlarged view of a latch and catch holding the two bracket assembliestogether.

DETAILED DESCRIPTION

A list of part numbers and corresponding part names used herein isprovided as follows:

As used herein, the relative directions up and down, above and below,top and bottom, upper and lower, refer to the vertical direction whenthe bracket 10 is fastened to a generally horizontal concrete form 12,which is the orientation shown in at least FIGS. 1, 8 and 12. The actualorientation of the concrete form may vary in which case the lateraldirection will change accordingly. The lateral direction is to the side,preferably but not necessarily in a horizontal plane generally parallelto the concrete form 12. Advantageously a side profile of the bracketmay resemble a high-heeled shoe, with the end of the bracket closest tothe concrete form 12 during use comprising the toe-end, with the heelend opposite thereto. The relative directions left and right, are withrespect to a view from the looking from the toe end to the heel end ofthe bracket 10.

Referring to FIGS. 1-7, the bracket 10 has a toe end adjacent theconcrete form 12 during use, with a heel end opposite the toe end. Aninner housing 14 and an optional outer housing 16 are at the heel end ofthe bracket, each housing extending along longitudinal housing axis 17during use. The inner housing 14 advantageously takes the form of a tubewith a generally closed bottom 15 while the outer housing 16 is tubularwith open ends. The housings 14, 16 are preferably cylindrical. At leasta first curved support 18 extending from the inner housing to the toeend of the bracket 10. The curved support 18 has first and second curvedsupport parts 20 a, 20 b, respectively, which together form a curvedtube having a cross-section larger than the diameter D of the tube 21 sothe larger cross-section can enclose the tube 21. The curved support 18preferably has a generally circular cross-section and extends along acurved longitudinal axis along the center of the curved support 21. Thatcurved longitudinal axis curves about an axis parallel to the concreteform 12 and to the concrete surface which is typically parallel to theconcrete form and curves from a toe-end adjacent the concrete form to agenerally vertical orientation when the form 12 is horizontal. The upperend of the curved support part 20 a is advantageously connected to andadvantageously forms a unitary portion of an injection molded bottom 15of the inner housing 14.

During use, a tubular conduit such as tube 21 (FIG. 3) having an outerdiameter D passes through the curved support 18 and its the curvedsupport parts 20 a, 20 b and preferably into at least one of thehousing(s) 14, 16. and is held in position by the bracket 10. Thecross-sectional diameter of the curved passage formed by the curvedsupport parts 20 a, 20 b has a diameter larger than D in a planeorthogonal to the curved central axis or longitudinal axis of thesupport tube. Thus, each the diameter of the cross-section for thesemi-circular cross-section of each curved support part 20 a, 20 b islarger than D.

An opening 19 (FIG. 4D) in the bottom 15 of the inner housing 16 allowsthe tube 21 to enter the inner housing, or allows the wires, cables, orother elongated members in the tube 21 to enter the inner housing 16.The tube 21 may comprise a flexible conduit, wire, cable or otherelongated member to be embedded in and pass through the concrete inwhich the bracket 10 is embedded. Advantageously, a base 22 extends fromthe toe end to the heel end of the bracket 10, preferably continuouslyin the form of a thin plate following the curvature of the curvedsupport 18 for at least a portion of the length of that curved support.

A housing support 24 extends between the base 22 and the inner housing16 at the heel end of the bracket. A heel support flange 25 extendsbetween the housing support 24 and the curved support 18 and the base22, preferably connecting to and forming a unitary portion of aninjection molded curved support part 20 a and base 22. The heel supportflange extends laterally between the inner housing 14 and the base 22 toprovide lateral support to the housing as well as to resist downwardforce if a worker steps on the inner housing during construction. Theheel support flange 25 provides vertical support, helps transmit forcesin the plane of the flange 25 and stiffens the bracket 10. The heelsupport flange 25 preferably connects to the support part 20 a along thecurved length of the bottom of the curved support part 20 a, until thatcurved support part becomes connected to the base 22.

A plurality of feet 26 and a central support 27 extend between the base22 and the concrete form 12 during use. The depicted base 22 has agenerally rectangular shape when viewed from the top or bottom, with afoot 26 at each of the four corners and a central support 27. Each foot26 is advantageously a short tube, preferably cylindrical, with acentral passage 28 therethrough to accommodate passage of a fastener toconnect the foot (and thus the bracket 10) to the concrete form 12during use. Threaded fasteners are preferred, although nails and otherfasteners are suitable. As such fasteners are well known in the art,they are not shown. The central support 27 is located at about themiddle of the length and width of the base 22 when viewed from the topor bottom. The central support 27 is also preferably tubular but has aslot (FIG. 2B) extending through opposing sides of the tube to allowconcrete to enter the tube during use. The feet 26 and central support27 have a lower end contacting the concrete form 12 during use, withtheir upper end connected to and preferably forming a unitary portion ofan injection molded base 22. The feet 26 and central support 27 transferdownward forces on the bracket 10 to the concrete form 12 on which thefeet and central support rest during use, so that if a worker stepsdownward on the bracket 10, the bracket doesn't break.

A stiffening flange 30 advantageously extends from the toe end towardthe heel end of the base 22, with the first curved support part 20 aconnected to the stiffening flange and optionally forming part of thestiffening flange. When the stiffening flange forms part of the firstcurved support part 20 a, the stiffening flange may have a topstiffening flange 30 and a bottom stiffening flange 31. For bracketshaving a single curved support 18, the stiffening flange 30 thusadvantageously comprises a bottom support flange 31 between the bottomof the curved support 18 and the base 22, and a top support flange 30extending upward from the top of the curved support part 20 a, with thecurved support 20 a connecting the bottom and top stiffening flanges 30,31.

Advantageously, the stiffening flange 30 and 31 have a plurality ofcatches 32 such as openings or recesses which engage a plurality ofresilient latches 34, but may have a plurality of longitudinallyextending laches. When a single curved support 18 is used, the bottomstiffening flange 31 advantageously extends a short distance from thebase 22 to the bottom of the curved support part 20 a and the topstiffening flange 30 extends from the top side of the curved supportpart 20 a in a generally vertical plane during use. The bottomstiffening flange 31 extends from the base 22 a distance sufficient toform latches or catches as mentioned above and as further describedlater.

The stiffening flange 30 on the top of the support part 20 a strengthensthe bracket against bending and breakage if a worker steps downward onthe bracket 10 during use, while the stiffening flange 31 on the bottomof the support 20 a provides openings forming catches or optionallyprovides laches, as described later. The stiffening flange 31 on thebottom of the curved support 18 continues from the toe end toward theheel end of the bracket, and extends between the bottom of the curvedsupport 18 and curved support part 20 a, to the top of the base 22. Forbrackets having a single curved support 18, the stiffening flange 30thus advantageously comprises a bottom support flange 31 between thebottom of the curved support 18 and the base 22, and a top supportflange 30 extending upward from the top of the curved support part 20 a,with the curved support 20 a connecting the bottom and top stiffeningflanges 30, 31.

The inner housing 14 has a plurality of external ridges extendingradially outward from housing axis 17 and spaced a uniform distanceapart and extending around a circumference of the inner housing. Theridges do not extend continuously around the circumference of the innerhousing, but are separated by a plurality of channels that arepreferably vertically aligned so the slots are parallel to thelongitudinal axis of the inner housing. Advantageously, the channels 48are formed so each ridge extends only part way around the outercircumference of the inner housing 14. From two to 10 channels arebelieved suitable, with 3 to 5 channels preferred. The drawings showthree channels 48 spaced unequally around the circumference of the innerhousing 12 so the sets of ridges are not all of the substantially thesame circumferential length and in the depicted embodiment two sets ofridges are of equal length and the third set of ridges is longer.

The ridges separated by channels form first, second and third sets ofoutwardly extending ridges 42, 44 and 46, respectively with interveningchannels 48 between the respective ridges of each set of ridges. Theridges within each set of ridges have the same part number as does theset of ridges, so that a plurality of ridges 42 form the first set ofridges 42. The channels 48 are advantageously parallel to longitudinalor axial housing axis 17 and may be referred to herein as axial channels48. The first set of ridges 42 extend between two intervening channels48 and extend for about a quarter of the way around a first partialcircumference of the inner housing 14. The second set of ridges 44 andthe channels 48 between those second ridges extend about a quarter wayaround the adjacent side or partial circumference of the inner housing14. The third set of ridges 46 and the channels 48 between those thirdridges extend about half way around the adjacent side or partialcircumference of the inner housing 14. The circumferential length of thesets of ridges 42, 44 and 46 are thus, advantageously not all the samelength.

The ridges 42, 44 and 46 are equally spaced apart along the axialdirection or longitudinal axis 17 of the inner housing 16. The ridges42, 44, 46 may be viewed as forming circumferential recesses in theouter surface of the inner housing 16, between each pair of ridges, withthe circumferential recesses being in communication with the channels48.

Advantageously, but optionally, the leading end of two adjacent ridges42 or two adjacent ridges 44 or two adjacent ridges 46 within each setof ridges may be joined by an axially extending end segment 50 (FIG. 1,4A, 4B), but the end segment 50 joins only two adjacent ridges and doesnot form a continuous axial line. As used herein, the leading end of aridge is the most clockwise end viewed along axis 17 when looking fromthe inner housing 16 toward the base 20. The trailing end of a ridge isthe most counterclockwise end when viewed along axis 17 when lookingfrom the inner housing 16 toward the base 20. Each adjacent pair ofridges joined by axially extending end segments 50 may be joined byoffset end segment 52 which also extends axially. Thus, the offset endsegment 52 is advantageously staggered axially to join every other ridge44, 46 or 48. The offset end segments 52 are also axially offset betweenthe sets of ridges 44, 46 and 48 so that each axial end segment 50 iscircumferentially adjacent to an offset end segment 52 (FIG. 1, 4A, 4B).The circumferential space between axial end segments 50 may form theaxial channel 48 when the end segments 50 are used. The circumferentialrecess formed by the offset end segments 52 and the two adjacent axialend segments 50 above and below each end segment 52, forms a lockingrecess for use with a locking lug as described later.

A latching member 54 (FIG. 2B) optionally extends slightly axially andparallel to the longitudinal axis from a location at or near the axiallyextending end segments 50 to form a snap lock connection with a lockinglug 56 engaged by the latching member 54. The latching member 54 islocated about the circumferential width of the locking lug 56 from theoffset end segment 52, to hold the locking lug against the offset endsegment during use, as will become apparent.

Referring to FIGS. 1, 6A, 6B and 7B, a plurality of locking protrusionsor locking lugs extend inward from the opposing inner sides of the outerhousing 16 to engage the circumferential recesses formed by the sets ofridges 42, 43, 44 and offset end segments 52 to interlock the inner andouter housings 14, 16. The protrusions may be hollow or solid and mayhave various shapes. As used herein, the locking protrusions arereferred to as locking lugs 56.

The locking lugs 56 are aligned in axial columns corresponding in numberto the number of longitudinal or axial channels 48. Each locking lug 56is sized in its circumferential direction to fit within one of thechannels 48 so the outer housing 16 can slide over and axially along theoutside of the inner housing 14 with the locking lugs moving along theaxial channels so the inner and outer housings can vary their combinedaxial length.

The sets of ridges 42, 44, 46 form sets of recesses in the outer surfaceof the inner housing that are in communication with the channels 48. Thelocking lugs 56 are axially spaced a distance to coincide with the axialspacing between the ridges to coincide and to coincide with thecircumferential recesses between those ridges. The locking lugs 56 maybe rotated axially into the circumferential recesses so the recessesrestrain axil motion of the locking lugs and outer housing 16 relativeto the inner housing 14.

The locking lugs 56 are sized to fit into the gaps formed by thestaggered axial end segments 50, 52 so that rotating the outer housing16 places the locking lugs 56 between two adjacent ridges 42, 44 or 46on the inner housing 14. The latching member 54 advantageously engages amating recess on the upper edge of the adjoining locking lug 56, tosnap-lock the outer housing 16 to the inner housing 14. The ends of theridges 42, 44, 46 and the axial end segments 50, 52 restrain rotation ofthe lugs 56 and also provide an axial strength if a worker strikes orsteps on the outer housing 16. Thus, the lugs 56 hit end segments 50, 52to stop axial movement of the tube 60 until the lugs are rotated intothe channels 48 a, 48 b.

The axial end segments and offset end segments 50, 52 may be omitted sothe locking lugs 56 may be rotated to fit between two adjacent ridges 42or 44 or 46 to restrain relative axial motion between the inner andouter housings 14, 16. The removal of the end segments 50, 52 does notrestrain relative rotation of the housings, but is believed to providesuitable axial support along the longitudinal axis of the inner housingto restrain relative axial motion of the housings. The use of axial endsegments 50 and offset end segments 52 reduces the circumferentialmotion and rotation about axis 17 compared to when those axial segments50, 52 are omitted. When omitted, the locking lugs may rotate withoutrestraint between the adjacent ridges or within the circumferentialrecess between such ridges. The axial segments 50 and/or 52 limit suchrotation about axis 17.

The ridges 42, 44, 46 extend for a majority of the length of the innerhousing and preferably extend the entire length or substantially theentire length of the inner housing along the longitudinal axis. Bysubstantially the entire length is meant about 90 percent or more of thespecified length. The space between the adjacent ridges within each setof ridges 42, 44, 46 is preferably the same, with only the ends of eachpair of ridges joined by axial end segments 50 and offset end segments52 being staggered. The axial space between the adjacent ridges 42, 44,46 is preferably larger than the axial length of the respective lockinglugs 56 so the locking lugs and outer housing can rotate relative to theinner housing. The offset end segments 52 and latching protrusion 54 maybe used to limit rotation and to retain the parts in the rotatedposition, respectively. Alternatively, a narrowing in the spacingbetween the adjacent ridges may be used to create a releasableinterference fit with the locking lugs to retain the inner and outerhousings in a desired relative rotation—once the axial length has beenset.

Outer housing 16 is provided with rotational interlock devices such ashousing threads 58, 60 on opposing upper and lower ends of the housing,respectively. Advantageous, internal threads 58 on the outer housing areon the upper end and external threads 60 are on the lower end.Advantageously, the upper threads 58 are located on the inside of anenlarged end 62 on the outer housing 16. The threads 58, 60 are matingthreads so a second outer housing 16 can be threadingly connected to afirst outer housing 16. The enlarged end 62 is formed by a largerdiameter but short, cylindrical upper end of the outer housing 16,forming a short, outwardly extending shoulder at the bottom of theenlarged end. The threads 58, 60 are preferably double lead threads withone lead beginning on an opposing side of the housing 16 than the otherlead. Rotational interlock devices other than threads can be used,including bayonet locks.

The depicted base 10 has an inner housing 14 with three channels 48 andthe outer housing 16 has three columns of locking lugs 56 located andsized to move axially along those channels 48. Those channels areadvantageously located so that one central channel is in the verticalplane of the flange 30 and the other two side channels are about 90° oneach side of that central channel, with a plane through the sidechannels preferably being generally parallel to the plane of the housingsupport 24. Thus, relative to the longitudinal axis 17, first and secondsets of ribs 42, 44 extend across a circumferential arc of close to butless than 90° while the third set of ribs 46 extend across acircumferential arc close to but less than 180°. The correspondinglocking lugs 56 are also located in three columns, spaced 90° apart, sothe locking lugs can coincide with the channels 48. This arrangement isbelieved to offer advantages in injection molding the bracket 10.

The outer surface of the outer housing 16 may have stiffening ribsextending outward therefrom. The depicted housing 16 circumferentialstiffening ribs 61 and axial stiffening ribs 63 extending parallel toaxis 17. The four circumferential stiffening ribs 61 are equally spacedalong the length of axis 17, while the four axial stiffening ribs arerotationally spaced about axis 17 every 90 degrees, for a housing 16that is about 2-3 inches diameter. The number of ribs may vary. The ribs61, 63 also help entrain the housing in the concrete, with thecircumferential ribs 61 resisting motion along axis 17 when entrained inconcrete, while the axial ribs 63 resist rotation about axis 17 whenentrained in concrete. Many other configurations of ribs may be used.

A cap 64 is configured to cover the top end of the outer housing 16 andto also cover the top end of the inner housing 14 and optionally hasappropriate connections to releasably connect to the inner and outerhousings 14, 16 and avoid unintended removal. But the cap 64 need not beconfigured to securely connect to the top end of the inner housing as itneed only be capable of covering the top end of the inner housing. Thepreferred use of the cap 64 is to releasably and securely connect to thetop of the outer housing 16. The cap 64 is preferably centered onlongitudinal housing axis 17 during use. Rotational interlock devicessuch as a bayonet mount or cap threads 66 are advantageously provided ona skirt depending from the outer periphery of the cap 64 and areconfigured to engage the rotational interlock device such as matingthreads 58 on the outer housing 16. Advantageously, when the bottom ofthe cap's skirt hits the shoulder formed by the enlarged end 62, the topsurface of the cap is flush with the end of the outer housing 16 andpositioned at or slightly below the surface of the finished concreteduring use. External cap threads 66 are believed preferable to internalcap threads because the top end of the outer housing is embedded inconcrete and the external threads place the threaded connection with theouter housing 16 inside the housing.

The cap 64 advantageously has flexible filaments 68 extending upwardfrom the top surface of the cap 64, preferably centered on and extendingalong housing axis 17 during use. The filaments 68 flex during finishingof the concrete surface and stick up above the finished concrete surfaceto identify the location of the cap 64 and associated housings 14, 16and the contents of the housings passing through the tube 21. The cap 64advantageously has one or more wrenching recesses 70 on its exterior orupper surface, configured to receive tools that rotate the cap and breakit free of any concrete entraining the cap. The shape of the recessesmay vary. A plurality of ribs 72 may be provided on the outer peripheryof the enlarged end 62 to make it easier to manually grip and rotate theouter housing 16, and to further lock the enlarged head in the concreteduring use.

As seen in FIG. 5B, the bottom side of the cap 64 has centeringprotrusions 72 in the form of two crossed bars forming an “X” shape,with the radially outward ends of the terminating before the dependingskirt of the cap. The space between the centering protrusions 72 and thedepending skirt of the cap receive the upper part of the inner housing14 to restrain lateral movement of the cap relative to the innerhousing, with the cap preventing concrete from entering the innerhousing when the cap 64 is placed over the inner housing. Optionally, acircular locking flange (not labeled) may extend downward from thebottom side of the cap 64, with the locking flange located inward of thedepending skirt on which cap threads 66 are formed. The locking flangemay be configured to trap the top part of the inner housing 14 betweenthe locking flange and the adjacent skirt of the cap 64, to moresecurely hold the cap to the inner housing. The locking flange is shownas continuous, but could be intermittent. As seen in FIGS. 1 and 5A, 5C,the wrenching recesses 70 do not interfere with the centeringprotrusions and locking flange as the radially outward end of thewrenching recesses terminate inward of the centering protrusions 72 andlocking flange.

Referring to FIGS. 1 and 4A-4D, the base 22 has a rear flange 80 at theheel end of the base, with two rear feet 26 connected to the rear flange80. The rear flange 80 is generally parallel with the toe end of thebase 22, with the base having an arch 82 between the toe end and heelend of the base. The housing support 24 has a truncated triangular shapewith the base of the triangle extending across the width of the base 22at the rear flange 80, and the top of the truncated triangular shapeending at or shortly below the inner housing 14, with a shortrectangular extension between the bottom of the inner housing and thetruncated top end of the triangular shape as best seen in FIGS. 2B, 4Band 4C. Alternatively described, the base of the housing support 24 isshaped like an isosceles trapezoid with the non-parallel legsconverging, and a rectangular portion 84 (FIG. 2B, 4B, 4C) extendingfrom the top of the isosceles trapezoid.

The housing support 24 provides lateral support and stability to theinner housing 14 by connecting the bottom of the inner housing to thebase 22 and provides further support in the plane of the bottomstiffening flange 31 by connecting to that stiffening flange and thecurved support part 20 a and the base 22. The rectangular top portion ofthe housing support allows the outer housing 16 to fit down over theinner housing 14 until the bottom of the cap 64 on the outer housinghits the top edge of the inner housing. It is believed suitable to havea rectangular housing support 24 extending downward from the bottom ofthe housing to the base 10, and having a width not greater than thewidth of the housing at the location of the housing support. But thewidth of the housing support 24 at the juncture with the bottom 15 ofthe inner housing 16 is relative small as its location is offset fromthe largest diameter of the inner housing. A larger support at theconcrete form 12 is believed more desirable. Thus, the triangular shapedportion of the housing support 24 is believed stronger and more stablethan a narrower, rectangular-shaped housing support as it provides for amore spread-apart support at the base 22 and the concrete form 12.

The housing support 24 is shown as connecting to the base 22 at thejuncture of the rear flange 80 and the arch 82. As seen in FIGS. 1, 2Aand 4A, the toe end of the base 22 curves with and is connected to thecurved support part 20 a, shortly before the recurve toward the rearflange 80 and its associated feet 26.

Referring to FIGS. 1, 2A and 4A, the bottom stiffening flange 31 mayextend from the base 22 at the toe end of the base, in a generallyvertical direction, and with upper stiffening flange 30 extendingvertically from a top side of the first support part 20 a, whichpreferably has a generally semi-circular cross-section when the tube 21has a circular cross-section. The cross-sectional shape of the curvedsupport 18 preferably conforms to the cross-sectional shape of the tube21. The top end of the curved support part 20 a and the top end of thetop stiffening flange 30 are both advantageously connected to the innerhousing 14, preferably connected to the bottom 15 of that inner housing.The base 22 is connected to the curved support part 20 a until alocation near the middle of the curved length of the curved support part20 a, at which the arch 82 begins to recurve downward to juncture of thehousing support 24 and the rear flange 80.

In the depicted embodiment, the toe-end of the base 22 extends beyondthe toe-end of the curved support 18, preferably by about an inch or so,but could be flush with the end of the curved support 18 or the curvedsupport could extend beyond the toe end of the base 22.

The depicted embodiment is aesthetically configured to have a profileresembling a high-heeled shoe with a prominent plate following thatprofile and having a visible, upwardly extending arch between the toeend and heel end that extends upward a distance of about 2-3 inches froma plane through the toe end of the base 22 and the rear flange 80. Thebase 22 has a rectangular outer profile when viewed from the top orbottom. The depicted base 22 has a width of about 3-4 inches and alength of about 6-8 inches.

The toe end of the base 22 is close to the concrete form 12 and isgenerally parallel to the concrete form 12 at the toe end. The spacebetween the base 12 and the concrete form 12 at the toe end isdetermined by the length of the feet 26 and central support 27 whichpreferably abut the concrete form 12 during use. A minimum offset ofabout 2-3 cm (about half an inch) is believed suitable. Longer lengthsof the feet 26 and central support 27 allow deeper entrainment in theconcrete but less lateral stability during construction before theconcrete is poured. Openings 19 through the base 22 at the toe end allowfree passage of air from beneath the toe-end of the plate and to allowconcrete to more easily entrain the toe-end of the plate and to avoidair pockets which may result in voids in the concrete. Four circularopenings 19 are shown in a square arrangement, but other shapes andarrangements and numbers of opening are believed suitable.

Except for the curved support part 20 b and outer housing 16, thebracket 10 is preferably injection molded in a single pour of plastic toform a unitary, injection molded part or assembly that is injectionmolded in its entirety at one time. The only parts of bracket 10 notformed during this unitary, injection molding operation are the curvedsupport part 20 b, outer housing(s) 16 and cap 64, as those parts arephysically separate, but may be later connected to complete thefunctional use and formation of the bracket 10.

As used herein, references to a unitary part refer to such an injectionmolded portion of bracket 10. This unitary, injection molded part orbracket 10 is different from separately made parts that are connectedtogether by various means such as welding, melting, adhesives orthreaded fasteners as such unitary, injection molded part is believed tobe stronger (when comparable materials are used), less expensive to makeand more consistent in material composition, shape, form, fit andstrength.

The tube 21 is usually contained in a protective tube 86 for embeddingin concrete. A protective tube made of corrugated material, orpolypropylene, or flexible polyvinyl chloride (PVC) tube are believedsuitable for use with bracket 10. While less desirable, a metal conduitis believed suitable for use with the bracket 10. The bracket 10 isbelieved especially suitable for use with tubes 21 of about 0.5 inchesdiameter, with protective tubes 86 of about 1.0 inches in diameter. Butby adjusting the materials and/or dimensions, various diameters of tubes21, 86 may be used for concrete slabs of different thickness.

The protective tubes 86 preferably have a connector end 88 with a latch90 or catch 92 thereon. Typically, a male latch member 90 more commonlyfound on the connectors but it could be a female recess or catch 92. Theentry end of the curved support 18 is advantageously enlarged and hasthe mating catch 92 or latch 90 thereon to provide a positive connectionholding the connector and protective tube to one of the curved supportparts 20 a and thus the base 22 and bracket 10.

In use, the concrete form 10 is placed where concrete will be poured,typically on a horizontal surface but possibly on a vertical surface.Fasteners pass through passages 27 in the feet 26 to secure the bracket10 to the concrete form 12. The tube 21 is inserted into the innerhousing 14 from the lateral side of the bracket 10 that is open. Adistal end of the tube 21 is inserted upward through the opening 19 inthe bottom 15 of that inner housing 14. If the tube 21 is inserteddownward through the opening 19, then the entire length of the tube mustpass through the opening, or the tube must be spliced. The tube 21 isthen placed into the open, curved length of the curved support part 20a. The curved support part 20 b is then snapped onto the curved supportpart 20 a to form the curved support 18 and to enclose the tube 21 inthat curved support. A plurality of latches 34 having hooked ends passthrough openings 34 shaped to allow passage of the laches and engage thehooked ends of the laches, form a latch and catch assembly. The firstand second curved support parts 20 a, 20 b thus snap together to form asnap-fit connection holding the tube 21 in position in the curvedsupport 18. Connecting the tube 21 to the curved support 18 and bracket10 may be done before the bracket is fastened to the concrete form. Itis easier to place the bracket 10 without the tube connected, but it ismore difficult to accurately place the bracket on the concrete form 12because of the length of the connected tube 21. Moreover, the curvatureof the curved support 18 can help the curved support frictionally engagethe tube 21 and resist the tube sliding down and out of the curvedsupport, especially when the curved support is slightly larger indiameter than the outer diameter D of the tube 21. As used herein,slightly larger in diameter refers to a 15% or less difference indiameter. A radius of curvature of 3 to 6 inches over a 90° bend isbelieved suitable for a seven to ten-inch-thick concrete slab. Lagerradii of curvature will be preferred for thicker slabs.

The height of the bracket 10 at the heel end of the bracket may beselected to be a minimum height just under a standard thickness of aconcrete slab. If the slab thickness is the same or slightly higher thanthe height of the bracket 10 at the heel end, then the cap 64 is placedover the open, top end of the inner housing 16 and releasably connectedto the inner housing by locking flange or by resting on the periphery ofthe inner housing 14. Concrete may then be poured to entrain the bracket10 and tube 21.

If the height of the bracket 10 at the heel end of the bracket issufficiently lower than the anticipated slab thickness, then the outerhousing 16 is used to adjust the height as needed. The outer housing 16is rotated about longitudinal housing axis 17 until its vertical columnsof locking lugs 56 align with the respective longitudinal channels 48 onthe outer surface of the inner housing 14. The outer housing 16 is moveddownward along axis 17 until the desired height to the top of the outerhousing is achieved, and then the outer housing is rotated about thehousing's longitudinal axis so the locking lugs 56 move between adjacentridges in the respective sets of ridges 42, 44 and 46—recognizing thenumber of rows of lugs 56, sets of ridges (42, 44, 46) and separatingchannels 48 will vary.

If the addition of one housing is insufficient to achieve the desiredheight, a second outer housing 16 can be connected to the first housingby engaging the external threads 58 of a second outer housing 16 withthe internal threads 60 of the first outer housing 16. By usingadditional housings 16, the height of the housing can be adjusted inlarge increments, with the ridges and locking lugs allowing for smallincremental adjustment of the height.

Advantageously, the locking lugs 56 are rotated about axis 17 to beplaced between a pair of offset end segments 52 and hit a narrowingbetween the offset end segments to limit rotation about the outerhousing's longitudinal axis. Advantageously, the locking lugs 56 engagevarious ones of the latching member 54 to releasably retain the engagedlocking lugs. The latching protrusions 54 may form a sufficiently largenarrowing of the space into which a locking lug 56 is inserted so as toform an interference fit that retains the locking lug. Advantageouslythough, the latching lug rotates past the latching member 54 so thatremoval requires rotating the outer housing 16 and the latching lugspast the latching protrusions 54, with the rotational resistanceprovided by the latching lugs being great enough to avoid accidentaldisengagement of the outer housing.

Once the height of the outer housing is set, the cap 64 is connected tothe outer housing. The way the cap connects to the housing can vary.Advantageously, a rotational connection is used, such as cap threads 66engaging mating housing threads 58 on the outer housing 16. In somesituations, it may be desirable to set the height of the bracket andboth housings 14, 26 before inserting the tube into the inner housing14. The tube 21 may be inserted into a connected inner and outer housing14, 16 before or after the bracket 10 is fastened to the concrete form.But adding the outer housing 16 can make the height of the housings 14,16 large and that may impede the user's ability to reach toward thebottom 15 of the inner housing and pull the end of a tube 21 or wires inthe tube, through the opening 19 in the bottom of the inner housing.

The desired height of the housing(s) 14, 16 include any heightattributable to the cap 64. Once the height of the housings 14, 16relative to the concrete support 12 are set and once the tube 21 issnapped into the curved support 18, the bracket 10 is ready forconcrete. Construction workers preparing the building site may step on,bump, knock or kick the bracket and it is designed to maintain theheight and orientation of the cap 64 parallel with the concrete form 12and the finished concrete surface. Before pouring concrete, filaments 68are connected to the cap 64 so they extend upward. When concrete ispoured over and around the bracket 10 and housings 14, 16, the openings19, the slotted central support 27, and the ridges 42, 44 and 46 helpentrain the bracket in the concrete. When the concrete is beingfinished, the flexible filaments bend to allow finishing around thehousings 14, 16 and cap 64, while identifying the location of thehousings and cap. When the concrete is set, a worker locates thefilaments, chips away any concrete covering the cap 64 and then removesthe cap to allow access to the tube 21 and any elongated members passingthrough the tube 21 and into the housings 14, 16.

The tube 21 may comprise any rigid or flexible tubing suitable for itsintended use. As used herein, flexible means the ability to be manuallyand repeatedly flexed numerous times through a substantial arc of 60 to90 degrees without breaking, whereas a rigid tube is substantiallycapable of maintaining its substantially straight shape without externalsupport when held horizontally from one end. The tube may be bendable soas to allow manually bending. Smurf tubing, or corrugated plasticconduit, is commonly used for the flexible tube 21.

Referring to FIGS. 8-11, two tubes 21 and two curved supports 18 may beused with one bracket 10. The previously described parts are almost allthe same and are given the same numbers and the detailed description isnot repeated. In this embodiment, the stiffening flange may comprise aplanar flange having a bottom part 30 and a top flange part 31, ratherthan having a first curved support part 20 a with its semi-circularsidewall forming part of the flange, and the flange 30 may thus extendas a vertical plate from the toe end to the heel end where it joins theheel support flange 25. A first curved support 18 is advantageously onone side of the stiffening flange 30, 31 and a second curved support 18is on the other side of the stiffening flange 30, 31. The first curvedsupport part 20 a opens to one lateral side of the stiffening flange 30,31 as previously described, and the second curved support part 20 aopens to the opposing lateral side in the same manner as previouslydescribed. As best seen in FIG. 11C, the curved support parts 20 a areon opposing sides of the stiffening flange 30, 31, opening to and facingopposing lateral directions so that when the second curved support partsare connected to the bracket 10 and flange(s) 30, 21 two support tubes18 are formed, one on each opposing side of the central stiffeningflange 30, 31. The two curved support parts 20 a advantageously have aportion of their curved cross-sectional wall form a unitary, injectionmolded part with the stiffening flange 30.

The lower stiffening flange 31 has a first plurality of openings orcatches at locations below each curved support part 20 a while the upperstiffening flange 30 has a second plurality of openings or catches 32above each curved support part 20 a, with each first and secondplurality of openings or catches being interleaved for connecting to thesecond curved support parts 20 b.

The latches 34 from the two support parts 20 b mate with the openings orcatches 32 in an interleaved or alternating manner as seen in FIGS. 8and 12A. Because the flange 30 is a vertical plate in thisconfiguration, curved support part 22 a is not part of the flange 30 inthis configuration, the flange 30 is offset to one side of each curvedsupport 18 and the latches 34 have to extend further to reach the bottomstiffening flange 30 and top stiffening flange 31. Thus, the latches 34appear longer in FIG. 8 than in FIG. 1.

The method may include concrete pouring and finishing steps. After theconcrete slab 23 is poured the slab is finished, usually by a bull floatstep and later by troweling and likely power troweling steps.Advantageously the top surface of the housing and cap are flush with orslightly below the concrete surface so the whiskers 78 extend above thesurface and flex with the various finishing steps to avoid cutting ordetachment. The embedded cap, housing, base and connector aresufficiently strong to support a worker stepping on the bracket 10 andhousing 14 during concrete finishing, and sufficiently strong to supportthe weight of the power trowel.

Referring to FIGS. 8 and 10, the stiffening flange 30, 31 at the toe endof the base has a lateral thickness that increases from the end of thecurved support parts 18 to the free end of stiffening flange 30, 31 andbase 22. The width or thickness of the stiffening flange increases inthe lateral direction to help spread apart the two connectors 88 andassociated protective tubes 86 so that the protective tubes are morereadily entrained in the concrete. Spreading the two protective tubes 86apart helps vent air from below the protective tubes and enhancesconcrete entrainment. The toe-end of the flange 30, 31 thus extendsbeyond the toe-end of the curved supports 18 and increases in lateraldimension along an axis parallel to the base 22 and the concrete form12. A short toe-end extension of about one inch in length with anincrease in lateral dimension of about 0.1 inch at the toe-end of thecurved support 18 to a lateral dimension of about 0.2 to 0.3 inches atthe toe end of the flange 30, 31 is believed suitable for a protectivetube 86 about one inch in diameter.

The method may include accessing the housing after the concrete hardens.When the concrete slab 23 is hardened, the whiskers identify thelocation of the housing and cap. Any thin layer of concrete covering thecap is removed, as needed. Tools, such as opposing jaws of channel gripsor screwdrivers are placed into wrenching recesses 76 as needed tounscrew or otherwise remove the cap 72. The ends of the tube 32 andother tubes, wires, elongated members 33, etc. are then accessible forfurther use or connection. Advantageously, the inner housing 14 andouter housing 16 provide sufficient volume to contain enough undamagedtube and elongated members 33 (e.g., tubes, wires, cables) to allow acoupling (FIG. 1) or other connection with the tube or other elongatedmembers 33 or other devices to be formed inside or near to the housing,after the concrete is poured.

Locking lugs 56 having a square shape about 0.2 to 0.3 inches on a sideand extending about the same distance inward from the outer housing 16,are believed suitable for housings about 2-3 inches in diameter. Abracket 10 of unitary, injection molded polyethylene, polypropylene,PVC, or other injection moldable plastic is believed suitable. Housings14, 16 about 2-3 inches in diameter and 2-3 inches high are believedsuitable. The bracket 10 is believed especially suitable for use forconcrete slabs with a thickness of at least 4 to 12 inches, preferablyfrom 7 to 10 inches thick.

The concrete form 12 is described as a generally horizontal surface anytypically comprises a sheet of plywood or a corrugated metal surface.But the concrete form 12 could comprise a surface formed by the ground,such as a leveled dirt surface, or the sides of a trench in the ground.If the bracket 10 is fastened to a vertical surface then the lateraldirection will be generally up and down.

The various parts of the assembly may be provided in a kit form. Thus,the base 10 and its integrally molded parts may be provided with thesecond curved support part 20 b and/or with one or more outer housings16 and one cap 64. Likewise, the base 10 having two curved supports 18may be provided in a kit form with two, second curved support parts 20b, two caps 64, and two outer housings 16, or multiples of two outerhousings 16.

As discussed in the summary and in the operation of the bracket, thereis also provided an improved method for forming the curved passagethrough a concrete slab.

As required, detailed embodiments of the present invention are disclosedherein; however, it is to be understood that the disclosed embodimentsare merely exemplary of the invention, which may be embodied in variousforms. Therefore, specific structural and functional details disclosedherein are not to be interpreted as limiting, but merely as a basis forthe claims and as a representative basis for teaching one skilled in theart to variously employ the present invention in virtually anyappropriately detailed structure.

The above description is given by way of example, and not limitation.Given the above disclosure, one skilled in the art could devisevariations that are within the scope and spirit of the invention.Further, the various features of this invention can be used alone, or invarying combinations with each other and are not intended to be limitedto the specific combination described herein.

What is claimed is:
 1. A bracket for holding at least one tube having across-sectional diameter D while being embedded in a concrete slabhaving a planned thickness T, comprising: a base having a toe end and aheel end with a plurality of feet extending downward from the base andending in a same horizontal plane; an inner cylindrical housingextending along a longitudinal housing axis, the inner housing locatedabove and connected to the heel end of the base by a housing support,the inner housing having an open top and a generally closed bottom withat least one opening in the bottom to receive the at least one tubeduring use, the inner housing having at least a first, second and thirdplurality of equally spaced, circumferential recesses on an outersurface of the inner housing, the inner housing having three axialchannels two of which are spaced 90°, each of the axial channels incommunication with two of the three circumferential recesses, each axialchannel being parallel to the housing axis; a tubular, outer housinghaving open top and bottom ends and extending along the housing axis andhaving a larger diameter than the inner housing to fit over the innerhousing, the outer housing having a plurality of locking lugs extendinginward with the locking lugs located in columns to move axially alongrespective ones of the axial channels separating the circumferentialrecesses, the locking lugs spaced axially to respectively align with thecircumferential recesses and sized to fit into the circumferentialrecesses when the outer housing is rotated relative to the inner housingto interlock the locking lugs with the circumferential recesses andadjust the relative positions of the inner and outer housings along thelongitudinal housing axis; and a first curved support having a firstcurved central axis with a first curved support part extending alongthat first curved central axis and having a first end connected to thetoe end of the base and a second end connected to the inner housing atthe bottom of the inner housing, the first curved support partconfigured to receive one side of a length of the at least one tubeduring use.
 2. The bracket of claim 1, further comprising a capconfigured to releasably connect to a top end of the outer housing. 3.The bracket of claim 1, wherein the first curved support includes asecond curved support part extending along the first central axis andhaving a cross-section in a plane orthogonal to the first central axisand connected to the first curved support part to form a tubular passagein the first curved support having a cross-section larger than D toreceive the at least one tube during use.
 4. The bracket of claim 3,wherein one of the first and second curved support parts has latches andthe other of the first and second curved support parts has catches toconnect the first and second curved support parts together.
 5. Thebracket of claim 1, wherein the first curved support includes a secondcurved support part extending along that first central axis and having across-section in a plane orthogonal to the first central axis andconnected to the first curved support part to form a tubular passagewith a cross-section larger than D to receive the at least one tubeduring use.
 6. The bracket of claim 3, wherein the first curved supportpart further comprises a top stiffening flange extending upward along atop side of the first curved support part and extending from a toe endof the first curved support part to the housing and connecting to thebottom of the housing, the top stiffening flange having one of a firstplurality of catches or a first plurality of latches and the secondcurved support part having the other of the first plurality of catchesor the first plurality of latches to interlock the top stiffening flangeand the second curved support part.
 7. The bracket of claim 6, whereinthe first curved support part further comprises a bottom stiffeningflange extending downward along a bottom side of the first curvedsupport part and extends from the toe end of the first curved supportpart to the housing support, the bottom stiffening flange having one ofa second plurality of catches or a second plurality of latches and thesecond curved support part having the other of the second plurality ofcatches or the second plurality of latches located to interlock thestiffening flange and the second curved support part.
 8. The bracket ofclaim 1, wherein the base has a generally rectangular shape when viewedfrom a bottom of the bracket, with a foot at each corner of the base,the base having an opening on each opposing side of the first curvedsupport part and at the toe end of the base to allow entrainment byconcrete during use, and wherein a bottom portion of the housing supportcomprises a triangular shaped plate.
 9. The bracket of claim 5, furthercomprising a central support extending from a middle of the basedownward and ending in the same plane as the feet.
 10. The bracket ofclaim 1, further comprising: a stiffening flange extending upward fromthe base and extending from the toe end to the heel end of the base andconnecting to the bottom of the housing and the housing support, thefirst curved support being located on a first side of the stiffeningflange; a second curved support located on a second side of thestiffening flange and having a second central axis and a third curvedsupport part extending along that second central axis, the third curvedsupport part having a first end connected to the base at the toe end ofthe base and having a second end connected to the bottom of the innerhousing and in communication with an inside of the inner housing, thethird curved support part having a cross-section in a plane orthogonalto the second central axis forming a portion of a tubular passage duringuse having a diameter larger than D.
 11. The bracket of claim 10,wherein the second curved support includes a fourth curved support partextending along the second central axis and having a semi-circularcross-section in a plane orthogonal to the second central axis andconnected to the second curved support to form the tubular passage witha cross-section having a diameter larger than D.
 12. The bracket ofclaim 3, wherein a toe end of the second curved support part has one ofa latch or catch to releasably connect to the other of a catch or alatch on a connector of a protective tube enclosing the tube having adiameter D during use of the bracket.
 13. The bracket of claim 1,further comprising: a second tubular, outer housing having open end andextending along the housing axis and having a larger diameter than theinner housing, each first and second outer housing having a plurality oflocking lugs extending inward with the locking lugs located in columnsto move axially along the channels separating the circumferentialrecesses, the locking lugs spaced axially to align with thecircumferential recesses and sized to fit into the circumferentialrecesses when either the first or second outer housing is rotatedrelative to the inner housing to interlock the mating projections withthe circumferential recesses and adjust the relative positions of theinner and outer housings along the longitudinal housing axis, each firstand second outer housing having top and bottom rotational interlockingdevices on respective top and bottom ends of each housing and configuredso the first interlocking device of the second housing may interlockwith the second interlocking device of the first housing to interconnectthe first and second housings along the longitudinal axis, with a capreleasably engaging the top interlocking device of the second housing,and the locking lugs of the first housing engaging the circumferentialrecesses on the outer surface of the inner housing.
 14. The bracket ofclaim 1, wherein the base comprises a rear flange located on an opposingside of the housing support as the first curved support, the rear flangehaving two feet, each on an opposing side of the rear flange.
 15. Thebracket of claim 1, wherein the cross-section is circular and has adiameter greater than D.
 16. A kit to form a bracket for holding atleast one tube having a cross-sectional diameter D while being embeddedin a concrete slab, comprising: a base having a toe end and a heel endwith a plurality of feet extending downward from the base and ending ina same horizontal plane, each foot having a passage therethrough for afastener; an inner cylindrical housing extending along a longitudinalhousing axis, the inner housing located above and connected to the heelend of the base by a housing support, the inner housing having an opentop and a generally closed bottom with at least one opening in thebottom to receive the at least one tube during use, the inner housinghaving at least a first, second, and third plurality of equally spaced,circumferential recesses on an outer surface of the inner housing, theinner housing having three axial channels two of which are spaced 90°,each of the axial channels in communication with two of the threecircumferential recesses, each axial channel being parallel to thehousing axis; a first curved support having a first central axis withfirst and second curved support parts each extending along the firstcurved central axis, the first curved support party having a first endconnected to the toe end of the base and a second end connected to theinner housing at the bottom of the inner housing, the first and secondcurved support parts forming a tubular passage with a cross-section in aplane orthogonal to the first central axis larger than D; a first,tubular, outer housing having opposing and open, top and bottom ends,the first outer housing having a larger diameter than the inner housingso it fits over the inner housing along the longitudinal axis, the firstouter housing having a plurality of locking lugs extending inward andlocated in columns to move axially along the channels separating thecircumferential recesses when the first outer housing moves along thehousing axis and over the inner housing, the locking lugs spaced axiallyto align with the circumferential recesses and sized to fit into thecircumferential recesses when the first outer housing and the innerhousing are rotated relative to each other to interlock the matingprojections with the circumferential recesses; and a removable cap forthe top end of the outer housing.
 17. The kit of claim 16, furthercomprising a second, tubular outer housing having open, top and bottomends, the second outer housing having a larger diameter than the innerhousing and fitting over the inner housing along the longitudinal axis,the second outer housing having a plurality of locking lugs extendinginward and located in columns to move axially along the channelsseparating the circumferential recesses, the locking lugs spaced axiallyto align with the circumferential recesses and sized to fit into thecircumferential recesses, the second outer housing having third andfourth rotational interlocking devices on the respective top and bottomends of the second outer housing, and configured to interlock with adifferent one of the first and second interlocking devices of the firstouter housing to interconnect the first and second outer housings alongthe longitudinal axis during use.
 18. The kit of claim 16, wherein thefirst outer housing has top and bottom rotational interlocking deviceson respective top and bottom ends of the first outer housing with thetop rotational interlocking device on the first outer housing configuredto releasably connect to the cap.
 19. The kit of claim 16, furtherincluding a stiffening flange extending from the toe end to the heel endof the base and connected to the housing support and the bottom of thehousing.
 20. The kit of claim 19, wherein the stiffening flange has afirst plurality of openings above the first curved support part and asecond plurality of openings below the first curved support part, thefirst and second plurality of openings forming catches for latchesextending from the second curved support part.
 21. The kit of claim 20,wherein the first curved support part forms a portion of the stiffeningflange.
 22. The kit of claim 20, wherein the stiffening flange hasopposing first and second laterally facing sides with the first curvedsupport part located on the first laterally facing side, and furthercomprising: a second curved support located on the second laterallyfacing side of the stiffening flange and having a second central axis,the second curved support having third and fourth curved support partseach extending along the second central axis, the third curved supportpart having a first end connected to the base at the toe end of the baseand having a second end connected to the bottom of the inner housing andin communication with an inside of the inner housing, the third andfourth curved support parts forming a tubular passage with across-section in a plane orthogonal to the first central axis largerthan D.
 23. A method of supporting a tube during the forming of aconcrete slab poured on a concrete form, using a bracket having a baseand a housing with a cap enclosing a top opening of the housing to allowaccess to the tube when the tube is inside the housing, the tubeextending along a curved axis between the concrete form and the plannedsurface, the method comprising the steps of: securing the tube to thebracket which bracket has a curved, tubular support extending along thecurved axis, the curved tubular support being separated along a verticalplane containing or parallel to the curved axis to form first and secondcurved support parts with the first curved support part beingpermanently affixed to the bracket, the securing step including placingthe tube into the first curved support part and passing an end of thesupport tube through an opening in the bottom of the housing whichcomprises an inner housing that is permanently affixed to the firstcurved support part, the securing step further including connecting thesecond curved support part to the bracket to form the first support tubeand enclose the tube along the curved axis; passing a tubular outerhousing having open ends and a larger diameter than the inner housingalong the housing axis until an axial column of axially spaced lockinglugs that extend inward from the outer housing align with at least afirst, second and third plurality of equally spaced, circumferentialrecesses that each encircle a portion of an outer circumference ofsurface of the inner housing to adjust the relative height of the innerand outer housings along the housing axis, the inner housing havingthree axial cannels two of which are spaced 90°, each of the axialchannels in communication with two of the three circumferentialrecesses; and fastening the bracket to the concrete form.
 24. The methodof claim 23, step of rotating one or both of the inner and outerhousings and moving at least some of the locking lugs into thecircumferential recesses.
 25. The method of claim 24, wherein therotating step occurs before the fastening step.
 26. The method of claim24, wherein the securing step occurs after the fastening step.
 27. Themethod of claim 24, wherein the step of connecting the second curvedsupport part to the bracket comprises engaging a plurality of latches onopposing top and bottom sides of the second curved support part withcatches on opposing top and bottom sides of the first curved supportpart.